Valve seats for use in fracturing pumps

ABSTRACT

A valve seat at least partially formed of a ceramic material for use in a fracturing pump includes a first body and a second body. The first body is configured to be inserted into a fluid passageway of the fracturing pump. The first body has an outer diameter, D1. The second body extends radially from the first body and has an outer diameter, D2, greater than the outer diameter, D1, of the first body. The second body is at least partially formed of the ceramic material.

CROSS-REFERENCE TO RELATED APPLICATION

This Application claims priority to and the benefit of U.S. ProvisionalPatent Application Ser. No. 61/909,197, filed on Nov. 26, 2013, which isincorporated herein by reference in its entirety.

TECHNICAL FIELD

This disclosure relates to reciprocating pumps, and, in particular, tovalve seats used in reciprocating pumps.

BACKGROUND OF THE DISCLOSURE

In oilfield operations, reciprocating pumps are used for differentapplications such as fracturing the subterranean formation, cementingthe wellbore, or treating the wellbore and/or formation. A reciprocatingpump typically includes a power end and a fluid end or cylindricalsection. The fluid end is typically formed of a one piece constructionor a series of blocks secured together by rods. The fluid end includesan opening for receiving a plunger or plunger throw, an inlet passage,an outlet passage, and an access port. Reciprocating pumps areoftentimes operated at pressures of 10,000 pounds per square inch (psi)and upward to 25,000 psi and at rates of up to 1,000 strokes per minuteor even higher during fracturing operations. A reciprocating pumpdesigned for fracturing operations is referred to as a frac pump.

During operation of a frac pump, a fluid is pumped into the fluid endthrough the inlet passage and out of the pump through the outletpassage. The inlet and outlet passages each include a valve assembly,which is a check type of valve that is opened by differential pressureof the fluid and allows the fluid to flow in only one direction. Thisfluid often contains solid particulates or corrosive material that cancause corrosion, erosion and/or pitting on surfaces of the valveassembly. One particular area of erosion and pitting generally occurs oninteracting surfaces of the valve assembly, which consists of a valveseat fixed into the inlet or outlet passages within the fluid end and avalve body that moves cyclically relative to the valve seat. Inoperation, the valve is operable between an open position, in which thevalve body is spaced apart from the valve seat to facilitate fluid flowthrough the valve, and a closed position, in which the valve bodycontacts and sealingly engages the valve seat.

During operation, solid particulates are oftentimes trapped between theinteracting surfaces of the valve body and the valve seat, causingerosion and pitting of these surfaces. Because the valve seat issecurely fastened within the fluid end, it is more difficult andcumbersome to replace the valve seat than the valve body. For example, avalve seat is oftentimes fixed inside the fluid passageway by way of aninterference fit; thus, removing the valve seat from the fluidpassageway oftentimes increases the risk of damage to the pump fluidend. There is a need to provide a valve having an increased resistanceto wear to address one or more of the foregoing issues, among others.

SUMMARY

In a first aspect, a valve seat at least partially formed of a ceramicmaterial for use in a fracturing pump includes a first body and a secondbody. The first body has an outer diameter D1 and is configured to beinserted into a fluid passageway of the fracturing pump. The second bodyextends radially from the first body and has an outer diameter, D2,greater than the outer diameter, D1. The second body at least partiallyformed of the ceramic material.

In certain embodiments, the second body is a tapered shoulder.

In other embodiments, the second body is a tapered shoulder extendingradially from the first body at an angle between five and seventy-fivedegrees.

In yet another embodiment, the valve seat is configured to sealinglyreceive a valve body.

In still another embodiment, the valve seat is formed from the ceramicmaterial.

In certain embodiments, only the second body is formed from the ceramicmaterial.

In other embodiments, at least a portion of the second body has an outercoating formed from the ceramic material.

In yet another embodiment, at least a portion of the second body has anouter coating formed from the ceramic material and wherein the outercoating is formed by spraying or dipping the at least the portion of thesecond body with the ceramic material.

In still another embodiment, at least a portion of the second body hasan outer coating formed from the ceramic material and wherein the outercoating has a thickness, t1, between approximately 1/32 inches and ½inches.

In certain embodiments, the second body includes an insert comprisingthe ceramic material.

In other embodiments, the second body includes an insert comprising theceramic material, wherein the insert is fixed to the second body bybonding, press-fit, shrink-fit, sintering, or combination thereof.

In yet another embodiment, the second body includes an insert comprisingthe ceramic material, wherein the insert has a height, ht, betweenapproximately 1/32 inches to ½ inches.

In still another embodiment, the second body includes an insertcomprising the ceramic material, and wherein the second body isconfigured such that the insert is positioned to contact at least aportion of a valve body to create a seal between the insert and theportion of the valve body.

In certain embodiments, the second body includes an insert comprisingthe ceramic material, and wherein the second body is configured suchthat the insert is positioned to contact at least a portion of a valvebody to create a seal between the insert and the portion of the valvebody.

In other embodiments, the second body includes an insert comprising theceramic material, and wherein the second body is configured such thatthe insert is positioned to contact at least a portion of a valve bodyto create a seal between the insert and the portion of the valve body,and wherein the ceramic material has a material hardness value, H1greater than a material hardness value, H2, of the valve body.

In yet another embodiment, the second body includes an insert comprisingthe ceramic material, and wherein the second body is configured suchthat the insert is positioned to contact at least a portion of a valvebody to create a seal between the insert and the portion of the valvebody, and wherein the insert is fixed to the second body by bonding,press-fit, shrink-fit, sintering, or combination thereof.

In still another embodiment, the second body includes an insertcomprising the ceramic material, and wherein the second body isconfigured such that the insert is positioned to contact at least aportion of a valve body to create a seal between the insert and theportion of the valve body, and wherein the insert has a height, ht,between approximately 1/32 inches to ½ inches.

In certain embodiments, the ceramic material comprises zirconia,tungsten carbide nickel, or tungsten carbide cobalt.

In a second aspect, a valve seat for use in a fracturing pump includes acylindrical body and a tapered shoulder. The cylindrical body has aninner surface and an opposing, outer surface, with the inner surfaceforming a bore along a longitudinal axis of the cylindrical body. Theouter surface is configured to be fitted against a first wall of thefracturing pump, wherein the first wall forms a first fluid passageway.The tapered shoulder extends radially from the cylindrical body and hasan inner surface and an opposing, outer surface. At least a portion ofthe inner surface is formed from a ceramic material. The outer surfaceis configured to be fitted against a second wall of the fracturing pump.The second wall forms a second fluid passageway that has a largerdiameter than the first fluid passageway.

In certain embodiments, the ceramic material comprises zirconia,tungsten carbide nickel, or tungsten carbide cobalt.

In a third aspect, a valve assembly for use in a fracturing pumpincludes a valve body and a valve seat. The valve body is moveablebetween an open position and a closed position, the valve body includesa head portion and a tail portion. The valve seat is at least partiallyformed of a ceramic material and includes a first body and a secondbody. The first body has an outer diameter, D1, and an inner diameter,D3, and is configured to receive the tail portion of the valve body. Thesecond body is at least partially formed of a ceramic material andextends radially from the first body. The second body has an outerdiameter, D2, that is greater than the outer diameter, D1, of the firstbody. The second body is configured to sealingly engage the head portionof the valve body.

In certain embodiments, a seal body is partially positioned within agroove formed in the head portion of the valve body such that the sealbody is configured to create a seal between the head portion of thevalve body and the second body of the valve seat when the valve body isin the closed position.

In other embodiments, a seal body is partially positioned within agroove formed in the head portion of the valve body such that the sealbody is configured to create a seal between the head portion of thevalve body and the second body of the valve seat when the valve body isin the closed position, and wherein the seal body is formed of anelastomeric material.

In yet another embodiment, the second body is a tapered shoulder.

In still another embodiment, the second body is a tapered shoulderextending radially from the first body at an angle between five andseventy-five degrees.

In certain embodiments, the entire valve seat is formed from the ceramicmaterial.

In other embodiments, a portion of the valve body is formed from theceramic material.

In yet another embodiment, at least a portion of the second body has anouter coating formed from the ceramic material.

In still another embodiment, at least a portion of the second body hasan outer coating formed from the ceramic material, wherein the outercoating is formed by spraying or dipping the at least the portion of thesecond body with the ceramic material.

In certain embodiments, at least a portion of the second body has anouter coating formed from the ceramic material, wherein the outercoating has a thickness, t1, between approximately 1/32 inches and ½inches.

In other embodiments, at least a portion of the second body has an outercoating formed from the ceramic material, wherein the outer coating hasa thickness, t1, between approximately 1/32 inches and ½ inches.

In yet another embodiment, the second body includes an insert comprisingthe ceramic material.

In still another embodiment, the second body includes an insertcomprising the ceramic material, wherein the insert is fixed to thesecond body by bonding, press-fit, shrink-fit, sintering, or combinationthereof.

In certain embodiments, the second body includes an insert comprisingthe ceramic material, wherein the insert has a height, ht, betweenapproximately 1/32 inches to ½ inches.

In certain embodiments, the second body includes an insert comprisingthe ceramic material, and wherein the second body is configured suchthat the insert is positioned to contact at least a portion of the headportion of the valve body.

In other embodiments, the second body includes an insert comprising theceramic material, and wherein the second body is configured such thatthe insert is positioned to contact at least a portion of the headportion of the valve body, wherein the ceramic material has a materialhardness value, H1 greater than a material hardness value, H2, of thevalve body.

In yet another embodiment, the second body includes an insert comprisingthe ceramic material, and wherein the second body is configured suchthat the insert is positioned to contact at least a portion of the headportion of the valve body, wherein the insert is fixed to the secondbody by bonding, press-fit, shrink-fit, sintering, or combinationthereof.

In still another embodiment, the second body includes an insertcomprising the ceramic material, and wherein the second body isconfigured such that the insert is positioned to contact at least aportion of the head portion of the valve body, wherein the insert has aheight, ht, between approximately 1/32 inches to ½ inches.

In certain embodiments, the ceramic material comprises zirconia,tungsten carbide nickel, or tungsten carbide cobalt.

In a fourth aspect, a valve assembly includes a valve body moveablebetween an open position and a closed position, a valve seat, and a sealbody. The valve seat is at least partially made from a ceramic materialand has an inner surface that forms a bore along a longitudinal axis ofthe valve seat for receiving at least a portion of the valve body and atapered surface extending outwardly from the inner surface. The sealbody is configured to contact an outer portion of the tapered surfacewhen the valve body is in the closed position to create a seal betweenthe outer portion and the valve body.

In certain embodiments, a gap is formed between an inner portion of thetapered surface and the valve body when the valve body is in the closedposition.

Other aspects, features, and advantages will become apparent from thefollowing detailed description when taken in conjunction with theaccompanying drawings, which are a part of this disclosure and whichillustrate, by way of example, principles of the inventions disclosed.

DESCRIPTION OF THE FIGURES

The accompanying drawings facilitate an understanding of the variousembodiments.

FIG. 1 is an elevational view of a reciprocating pump assembly accordingto an exemplary embodiment, the reciprocating pump assembly includes afluid cylinder assembly.

FIG. 2 is a cross-sectional view of the fluid cylinder assembly of FIG.1 according to an exemplary embodiment, the fluid cylinder assemblyincludes a fluid cylinder having inlet and outlet valve assemblies, eachof the valve assemblies including a valve seat.

FIG. 3 is an enlarged view of the inlet valve assembly illustrated inFIG. 2, according to an exemplary embodiment.

FIG. 4 is a cross-sectional view of a valve seat according to anexemplary embodiment.

FIG. 5 is a cross-sectional view of a valve seat according to anotherexemplary embodiment.

FIG. 6 is a cross-sectional view of a valve seat according to yetanother exemplary embodiment.

FIG. 6C is an enlarged view of a portion of the valve seat of FIG. 6.

FIG. 7 is a cross-sectional view of a valve seat according to anotherexemplary embodiment.

FIG. 7C is an enlarged view of a portion of the valve seat of FIG. 7.

FIG. 8 is a cross-sectional view of a valve seat according to anotherexemplary embodiment.

FIG. 9 is a cross-sectional view of a valve seat according to anotherexemplary embodiment.

DETAILED DESCRIPTION

Referring to FIGS. 1-3, an illustrative embodiment of a reciprocatingpump assembly 100 is presented in which an insert 196 (FIG. 3) isemployed to reduce damage to, and thus, extend the operating life of, avalve assembly 143, due to corrosion, erosion, pitting or the like. Inthe embodiment illustrated in FIGS. 1-3, the insert 196 is formed of ahigh strength ceramic material; however, it should be understood thatinsert 196 may be otherwise formed. In FIGS. 1-3, the reciprocating pumpassembly 100 includes a power end portion 102 and a fluid end portion104 operably coupled thereto. The power end portion 102 includes ahousing 106 in which a crankshaft (not shown) is disposed, thecrankshaft is driven by an engine or motor (not shown). The fluid endportion 104 includes a fluid end block or fluid cylinder 108, which isconnected to the housing 106 via a plurality of stay rods 110. Inoperation and as discussed in further detail below, the crankshaftreciprocates a plunger rod assembly 120 between the power end portion102 and the fluid end portion 104. According to some embodiments, thereciprocating pump assembly 100 is freestanding on the ground, ismounted to a trailer for towing between operational sites, or is mountedto a skid.

Referring to FIGS. 1 and 2, the plunger rod assembly 120 includes aplunger 122 extending through a bore 124 and into a pressure chamber 126formed in the fluid cylinder 108. At least the bore 124, the pressurechamber 126, and the plunger 122 together may be characterized as aplunger throw. According to some embodiments, the reciprocating pumpassembly 100 includes three plunger throws (i.e., a triplex pumpassembly); however, in other embodiments, the reciprocating pumpassembly includes a greater or fewer number of plunger throws.

In the embodiment illustrated in FIG. 2, the fluid cylinder 108 includesfluid inlet and outlet passages 128 and 130 formed therein, which aregenerally coaxially disposed along a fluid passage axis 132. Asdescribed in greater detail below, fluid is adapted to flow through thefluid inlet and outlet passages 128 and 130 and along the fluid passageaxis 132.

In the embodiment illustrated in FIG. 2, an inlet valve assembly 144 isdisposed in the fluid inlet passage 128 and an outlet valve assembly 146is disposed in the fluid outlet passage 130. In FIG. 2, the valveassemblies 144 and 146 are spring-loaded, which, as described in greaterdetail below, are actuated by at least a predetermined differentialpressure across each of the valve assemblies 144 and 146.

Referring to FIG. 3, the inlet valve assembly 144 includes a valve seat166 and a valve body 168 engaged therewith. The valve seat 166 includesa first or cylindrical body 170 having an inner surface 172 and anopposing outer surface 174. The inner surface 172 forms a bore 176 alonga valve seat axis 178 of the valve seat 166, which is coaxial with thefluid passage axis 132 when the inlet valve assembly 144 is disposed inthe fluid inlet passage 128. The outer surface 174 of the cylindricalbody 170 contacts an inside surface 136 of the fluid cylinder 108. Asealing element 177, such as an o-ring, is disposed in an annular groove1179 formed in the outer surface 174 of the cylindrical body 170 tosealingly engage the inside surface 136 of the fluid inlet passage 128.According to sonic embodiments, the cylindrical body 170 forms aninterference fit or is press fit against the inside surface 136 so thatthe valve seat 166 is securely fastened within the fluid inlet passage128. The cylindrical body 170 has an outer diameter, D1, and an innerdiameter, D3, as best illustrated in FIG. 4. According to certainembodiments, at least a portion of the valve seat 166 or valve body 168is formed from stainless steel.

Referring to FIGS. 3 and 4, the valve seat 166 further includes a secondbody 180 having a tapered shoulder that extends radially from the firstbody 170. The second body 180 has an inner surface 181 and an opposing,outer surface 183. The outer surface 183 contacts and otherwise abutsagainst the inside surface 136 of the fluid inlet passage 128 (FIG. 3).In an exemplary embodiment, the tapered shoulder 180 extends at an angle186 from the valve seat axis 178, which angle ranges from about 5degrees to about 90 degrees. The second body 180 has an outer diameter,D2, greater than the outer diameter, D1, of the first body 170.

According to certain embodiments, insert 196 is formed from a ceramicmaterial. In an exemplary, non-limiting embodiment, the ceramic materialmay be zirconia, partially stabilized zirconia, a tungsten carbide suchas tungsten carbide nickel, or tungsten carbide cobalt, titaniumcarbide, silicon nitride, or sialon. The hardness of the ceramicmaterial may range from about 12 to 22 GPa with reference to the Vickershardness number. In certain embodiments, the entire valve seat 166 andthe valve body 168 may be formed from ceramic material or only a portionof one or both of the valve seat 166 and the valve body 168 may beformed from the ceramic material. In certain embodiments, the insert 196is fixed to the valve seat 166 or the valve body 168 by a press-fit,shrink-fit, bonding, sintering, welding or combinations thereof. Inother embodiments, the ceramic material is a coating applied by dippingor spraying. The portions formed from ceramic are generally harder thanthe surrounding materials. In operation, the insert 196 is used toextend the life span of the valve assembly 143, which is subject tocorrosion, erosion, or pitting during operation.

Referring to FIGS. 1-3, the valve body 168 includes a tail portion 182,from which a head portion 184 extends radially outward. An annularcavity 188 is formed in the head portion 184 to receive a seal 190 tosealingly engage at least a portion of the inner surface 181 of thevalve seat 166. In the embodiment illustrated in FIG. 3, for example,the head portion 184 further includes a distal end 185 configured tosealingly engage at least a portion of the inner surface 181. Accordingto some embodiments, the distal end 185 has a material hardness lessthan the material hardness of the inner surface 181. In an alternativeembodiment, the distal end 185 has a material hardness substantiallyequal to the inner surface 181. In this configuration, the valve body168 typically wears faster, and thus, needs to be replaced before thevalve seat 166. One skilled in the art will appreciate that the valvebody 168 is generally easier, and thus cheaper, to replace than thevalve seat 166.

With continued referenced to FIG. 3, the tail portion 182 includes aplurality of circumferentially-spaced legs 187 angularly extending fromthe head portion 184 to slidably engage the inside surface 172 of thecylindrical body 170. In FIG. 3, the head portion 184 is engaged andotherwise biased by a spring 194, which, as discussed in greater detailbelow, biases the valve body 170 to a closed position, to prevent fluidflow.

In the embodiment illustrated in FIG. 3, for example, the seal 190 ismolded in place in the head portion 184. In other embodiments, the seal190 is preformed and then attached to the head portion 184. According tosome embodiments, the seal 190 is composed of one or more materials suchas, for example, a deformable thermoplastic material, a urethanematerial, a fiber-reinforced material, carbon, glass, cotton, wirefibers, cloth, and/or any combination thereof. In other embodiments, theseal 190 is composed of a cloth, which is disposed in a thermoplasticmaterial. According to some embodiments, the cloth includes carbon,glass, wire, cotton fibers, and/or any combination thereof. In yet otherembodiments, the seal 190 is composed of at least a fiber-reinforcedmaterial, which can prevent at least reduce delamination. According toembodiments disclosed herein, the seal 190 has a hardness of 95 Adurometer or greater, or a hardness of 69 D durometer or greater basedon the Rockwall Hardness scale. In several exemplary embodiments, thehead portion 184 is harder and more rigid than the seal 190.

In the embodiment illustrated in FIG. 2, the outlet valve assembly 146is be identical to the inlet valve assembly 144 and therefore will notbe described in further detail.

With reference to FIGS. 1-3, operation of the reciprocating pumpassembly 100 is discussed. In operation, the plunger 122 reciprocateswithin the bore 124 for movement in and out of the pressure chamber 126.That is, the plunger 122 moves back and forth horizontally, as viewed inFIG. 2, away from and towards the fluid passage axis 132 in response torotation of the crankshaft (not shown) that is enclosed within thehousing 106. As the plunger 122 moves in the direction of arrow 116 outof the pressure chamber 126, the inlet valve 144 is opened. Moreparticularly, as the plunger 122 moves away from the fluid passage axis132 in the direction of arrow 116, the pressure inside the pressurechamber 126 decreases, creating a differential pressure across the inletvalve 144 and causing the valve body 168 to move upward in the directionof arrow 118, as viewed in FIGS. 2 and 3, relative to the valve seat166. As a result of the upward movement of the valve member 168, thespring 194 is compressed and the seal 190 separates from the innersurface 181 of the tapered shoulder 180 to the open position. Fluidentering through the fluid inlet passage 112 (FIG. 1) flows along theaxis 132 and through the inlet valve 144, being drawn into the pressurechamber 126. To flow through the inlet valve 144, the fluid containingparticulates flows through the bore 176 of the valve seat 166 and alongthe valve seat axis 178. During the fluid flow through the inlet valve144 and into the pressure chamber 126, the outlet valve 146 is in itsclosed position, with the seal 190 of the valve body 168 of the outletvalve 146 engaging the inner surface 181 of the tapered shoulder 180.Fluid continues to be drawn into the pressure chamber 126 until theplunger 122 is at the end of its stroke farthest away from the fluidpassage axis 132. At this point, the differential pressure across theinlet valve 144 is such that the spring 194 of the inlet valve 144begins to decompress and extend, forcing the valve member 168 of theinlet valve 144 to move downward in the direction of arrow 119, asviewed in FIGS. 2 and 3. As a result, the e inlet valve 144 moves to andis otherwise placed in the closed position, with the seal 190 and thedistal end 185 sealingly engaging the inner surface 181.

As the plunger 122 moves in the direction of arrow 117 into the pressurechamber 126, the pressure within the pressure chamber 126 increases. Thepressure increases until the differential pressure across the outletvalve 146 exceeds a predetermined set point, at which point the outletvalve 146 opens and permits fluid to flow out of the pressure chamber126, along the fluid passage axis 132 through the outlet valve. As theplunger 122 reaches the end of its stroke towards the fluid passage axis132 (i.e., its discharge stroke), the inlet valve 144 is positioned inthe closed position, with the seal 190 and the distal end 185 sealinglyengaging the inner surface 181. Because particulates from the e fluidoftentimes become trapped between the contacting surfaces of the valvebody 168 and the valve seat 170, the ceramic insert 196 reduces and/orotherwise prevents the wear of the valve body 168 and/or the valve seat166. For illustrative purposes, the ceramic insert 196 is only shown asbeing positioned in the valve seat 166; however, it should beappreciated that the ceramic insert 196 may be positioned in both thevalve body 168 and the valve seat 166 to prevent wear.

Referring now to FIGS. 3-9, multiple exemplary embodiments of theceramic insert 196 are illustrated. As previously mentioned, the entirevalve seat 166 or the entire valve body 168 may be formed from ceramicmaterial. Alternatively, only a portion 192 of the valve seat 166 or thevalve body 168 may be formed of ceramic, which, for illustrativepurposes, is referred to herein as the ceramic insert 196. In anexemplary, non-limiting embodiment, the ceramic material may bezirconia, partially stabilized zirconia, a tungsten carbide such astungsten carbide nickel, or tungsten carbide cobalt, titanium carbide,silicon nitride, or sialon. In certain embodiments, the ceramic materialmay be a refractory material such as oxides of aluminum, silicon, and/ormagnesium. In use, the ceramic insert 196 extends the life span of thevalve seat 166 or valve body 168 in areas that are subject fail frommany factors such as, but not limited to, corrosion, erosion, and/orpitting.

According to some embodiments, the hardness, H1, of the ceramic materialranges from about 12 to 22 GPa with reference to the Vickers hardnessnumber, and the hardness the ceramic insert 196 being harder than othersurrounding areas. For example, the valve seat 166 includes the ceramicinsert 196 having the hardness, H1, that is greater than a hardness, H2,of the adjacent valve seat 166 material or of the contact surface of thevalve body 168, which may include the seal 190 and the end portion 185.In one embodiment, the valve seat 166 and the valve body 168 are formedfrom stainless steel with the ceramic insert 196 formed from a ceramic.

According to embodiments disclosed herein, the ceramic insert 196 issecured by bonding, press-fitting, shrink-fitting, sintering, welding orcombinations thereof. As shown in FIGS. 4-7 and 9, the ceramic insert196 has a height, h1. In some embodiments, the height, h1, is betweenabout 1/32 inches to about ½ inches. In other embodiments, the ceramicinsert 196 is a coating 195 that is applied by dipping or spraying,having a thickness, t1, as shown in FIG. 8. In the embodimentillustrated in FIG. 8, the thickness, t1, is between about 1/32 inchesand ½ inches, however, such thickness may vary.

The ceramic insert 196 is formed of different shapes and sizes, andadditionally and/or alternatively, may be a coating as shown in FIG. 8.The ceramic insert 196 is positioned in areas of high erosion andpitting. The size, shape, and placement of the ceramic insert 196depends on the operational environment. The ceramic insert 196 may besized, shaped, or placed based on areas of the valve assembly 144 thatare subject to the most erosion or pitting. Likewise, variances inoperational, ambient, or environmental temperatures, along with theoperational forces applied to and/or otherwise acting on the insert 196(e.g., the tensile and compressive forces) may affect the size, shape orplacement of the ceramic insert 196. According to some embodiments, theceramic insert 196 spans the entire inner surface 181 of the taperedshoulder 180. In one embodiment, the ceramic insert 196 only spans aportion of the inner surface 181 of the tapered shoulder 180.

FIG. 4 illustrates the ceramic insert 196 positioned in the valve seat166. The ceramic insert 196 is illustrated within a cavity 250 formed inthe valve seat 166 by sidewalls 250 a, 250 b and 250 c. In oneembodiment, the contact surface 196 c of the ceramic insert 196 is flushwith the surrounding contact surface 166 c of the valve seat 166. In oneembodiment (not shown), the contact surface 196 c of the ceramic insert196 is raised relative to the contact surface 166 c of the valve seat166. The ceramic insert 196 may be bonded in place. FIG. 5 illustratesthe ceramic insert 196 positioned in the valve seat 166 and surroundedby only two sides 250 a and 250 c of the valve seat 166.

FIGS. 6 and 6C illustrate the ceramic insert 196 having an “I-beam”shape disposed within the cavity 250 so as to be surrounded by the valveseat 166. An embodiment provides that the complicated shape of theceramic insert 196 shown in FIGS. 6 and 6C, may be secured in thesurrounding valve seat 166 by process of sintering.

FIGS. 7 and 7C illustrate the ceramic insert 196 having an “I-beamshape” positioned within a groove 198. An o-ring 199 is positionedaround the ceramic insert 196 to help keep the ceramic insert 196 inplace. The ceramic insert 196 may be bonded, shrink-fitted, orpress-fitted into the groove 198.

FIG. 9 illustrates the ceramic insert 196 held within the valve seat 166by tabs 200. The ceramic insert 196 is position within the valve seat166 by way of sintering. The ceramic insert 196 extends underneath thetabs 200 and may provide support beneath the tabs.

In the foregoing description of certain embodiments, specificterminology has been resorted to for the sake of clarity. However, thedisclosure is not intended to be limited to the specific terms soselected, and it is to be understood that each specific term includesother technical equivalents which operate in a similar manner toaccomplish a similar technical purpose. Terms such as “clockwise” and“counterclockwise”, “left” and right”, “front” and “rear”, “above” and“below” and the like are used as words of convenience to providereference points and are not to be construed as limiting terms.

In this specification, the word “comprising” is to be understood in its“open” sense, that is, in the sense of “including”, and thus not limitedto its “closed” sense, that is the sense of “consisting only of”. Acorresponding meaning is to be attributed to the corresponding words“comprise”, “comprised” and “comprises” where they appear.

In addition, the foregoing describes only some embodiments of theinvention(s), and alterations, modifications, additions and/or changescan be made thereto without departing from the scope and spirit of thedisclosed embodiments, the embodiments being illustrative and notrestrictive.

Furthermore, invention(s) have been described in connection with whatare presently considered to be the most practical and preferredembodiments, it is to be understood that the invention is not to belimited to the disclosed embodiments, but on the contrary, is intendedto cover various modifications and equivalent arrangements includedwithin the spirit and scope of the invention(s). Also, the variousembodiments described above may be implemented in conjunction with otherembodiments, e.g., aspects of one embodiment may be combined withaspects of another embodiment to realize yet other embodiments. Further,each independent feature or component of any given assembly mayconstitute an additional embodiment.

What is claimed is:
 1. A valve seat at least partially formed of aceramic material for use in a fracturing pump, the valve seatcomprising: a first body configured to be inserted into a fluidpassageway of the fracturing pump, the first body having an outerdiameter, D1; and a second body extending radially from the first bodyhaving an outer diameter, D2, greater than the outer diameter, D1, thesecond body at least partially formed of the ceramic material.
 2. Thevalve seat of claim 1, wherein the second body is a tapered shoulder. 3.The valve seat of claim 1, wherein the second body is a tapered shoulderextending radially from the first body at an angle between five andseventy-five degrees.
 4. The valve seat of claim 1, wherein the valveseat is configured to sealingly receive a valve body.
 5. The valve seatof claim 1, wherein the valve seat is formed from the ceramic material.6. The valve seat of claim 1, wherein only the second body is formedfrom the ceramic material.
 7. The valve seat of claim 1, wherein atleast a portion of the second body has an outer coating formed from theceramic material.
 8. The valve seat of claim 7, wherein the outercoating is formed by spraying or dipping the at least the portion of thesecond body with the ceramic material.
 9. The valve seat of claim 7,wherein the outer coating has a thickness, t1, between approximately1/32 inches and ½ inches.
 10. The valve seat of claim 1, wherein thesecond body includes an insert comprising the ceramic material.
 11. Thevalve seat of claim 10, wherein the insert is fixed to the second bodyby bonding, press-fit, shrink-fit, sintering, or combination thereof.12. The valve seat of claim 10, wherein the insert has a height, ht,between approximately 1/32 inches to ½ inches.
 13. The valve seat ofclaim 1, wherein the second body includes an insert comprising theceramic material, and wherein the second body is configured such thatthe insert is positioned to contact at least a portion of a valve bodyto create a seal between the insert and the portion of the valve body.14. The valve seat of claim 13, wherein the ceramic material has amaterial hardness value, H1 greater than a material hardness value, H2,of the valve body.
 15. The valve seat of claim 13, wherein the insert isfixed to the second body by bonding, press-fit, shrink-fit, sintering,or combination thereof.
 16. The valve seat of claim 13, wherein theinsert has a height, ht, between approximately 1/32 inches to ½ inches.17. The valve seat of claim 1, wherein the ceramic material compriseszirconia, tungsten carbide nickel, or tungsten carbide cobalt.
 18. Avalve seat for use in a fracturing pump, the valve seat comprising: acylindrical body having an inner surface and an opposing, outer surface,the inner surface forming a bore along a longitudinal axis of thecylindrical body, the outer surface configured to be fitted against afirst wall of the fracturing pump, wherein the first wall forms a firstfluid passageway; and a tapered shoulder extending radially from thecylindrical body having an inner surface and an opposing, outer surface,at least a portion of the inner surface formed from a ceramic material,the outer surface configured to be fitted against a second wall of thefracturing pump; wherein the second wall forms a second fluid passagewaythat has a larger diameter than the first fluid passageway.
 19. Thevalve seat of claim 18, wherein the ceramic material comprises zirconia,tungsten carbide nickel, or tungsten carbide cobalt.
 20. A valveassembly for use in a fracturing pump, the valve assembly comprising: avalve body moveable between an open position and a closed position, thevalve body having a head portion and a tail portion; and a valve seat atleast partially formed of a ceramic material, the valve seat comprising:a first body having an outer diameter, D1, and an inner diameter, D3,the first body configured to receive the tail portion of the valve body;and a second body at least partially formed of a ceramic materialextending radially from the first body and having an outer diameter, D2,greater than the outer diameter, D1, of the first body, the second bodyconfigured to sealingly engage the head portion of the valve body. 21.The valve assembly of 20 further comprising a seal body partiallypositioned within a groove formed in the head portion of the valve body,the seal body configured to create a seal between the head portion ofthe valve body and the second body of the valve seat when the valve bodyis in the closed position.
 22. The valve assembly of claim 21, whereinthe seal body is formed of an elastomeric material.
 23. The valveassembly of claim 20, wherein the second body is a tapered shoulder. 24.The valve assembly of claim 20, wherein the second body is a taperedshoulder extending radially from the first body at an angle between fiveand seventy-five degrees.
 25. The valve assembly of claim 20, whereinthe entire valve seat is formed from the ceramic material.
 26. The valveassembly of claim 20, wherein a portion of the valve body is formed fromthe ceramic material.
 27. The valve assembly of claim 20, wherein atleast a portion of the second body has an outer coating formed from theceramic material.
 28. The valve assembly of claim 27, wherein the outercoating is formed by spraying or dipping the at least the portion of thesecond body with the ceramic material.
 29. The valve assembly of claim27, wherein the outer coating has a thickness, t1, between approximately1/32 inches and ½ inches.
 30. The valve assembly of claim 20, whereinthe second body includes an insert comprising the ceramic material. 31.The valve assembly of claim 30, wherein the insert is fixed to thesecond body by bonding, press-fit, shrink-fit, sintering, or combinationthereof.
 32. The valve assembly of claim 30, wherein the insert has aheight, ht, between approximately 1/32 inches to ½ inches.
 33. The valveassembly of claim 20, wherein the second body includes an insertcomprising the ceramic material, and wherein the second body isconfigured such that the insert is positioned to contact at least aportion of the head portion of the valve body.
 34. The valve assembly ofclaim 33, wherein the ceramic material has a material hardness value, H1greater than a material hardness value, H2, of the valve body.
 35. Thevalve assembly of claim 33, wherein the insert is fixed to the secondbody by bonding, press-fit, shrink-fit, sintering, or combinationthereof.
 36. The valve assembly of claim 33, wherein the insert has aheight, ht, between approximately 1/32 inches to ½ inches.
 37. The valveassembly of claim 20, wherein the ceramic material comprises zirconia,tungsten carbide nickel, or tungsten carbide cobalt.
 38. A valveassembly comprising: a valve body moveable between an open position anda closed position; a valve seat at least partially made from a ceramicmaterial, the valve seat having an inner surface that forms a bore alonga longitudinal axis of the valve seat for receiving at least a portionof the valve body and a tapered surface extending outwardly from theinner surface; and a seal body configured to contact an outer portion ofthe tapered surface when the valve body is in the closed position tocreate a seal between the outer portion and the valve body.
 39. Thevalve assembly of 38, wherein a gap is formed between an inner portionof the tapered surface and the valve body when the valve body is in theclosed position.